GBC PRO-TECH DS-60 User manual

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© 1998 GBC Pro-Tech
Do not duplicate without written permission
GBC Pro-Tech
4151 Anderson Road
De Forest, Wisconsin 53532
Tel: [phone]
Part Number 930-006 Rev. A
Fax: [phone]
©1994HCS,Inc.800-748-0241ReorderNo.1033-PT
Crushand burn
hazard. Stay clear
ofmoving rollers.
Stopmachine and
raiseroll before
cleaning.
WARNING
ACHTUNG
MISEEN GARDE
©1994HCS,Inc.800-748-0241 ReorderNo.1033R-PT
Crushand burn
hazard. Stay clear
ofmoving rollers.
Stopmachine and
raiseroll before
cleaning.
WARNING
ACHTUNG
MISEEN GARDE
NOT
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M
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©1994HCS,Inc.800-748-0241 ReorderNo.7002-PT
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
1.Read and understand the Operation
Manualand all safety labels before
operatingthis machine.
2.Only a trained person is to be
permittedto operate this machine.
Trainingshouldinclude instruction
inoperation under normal conditions
andemergency situations.
3.This machine is to be serviced only
bytrained and authorized personnel.
Followlockoutprocedures before
servicing.
4.Never reach into the machine for any
reasonunless the machine is at a
COMPLETESTOP.
5.Never leave the machine stopped in
sucha manner that another worker can
startthe machine while you are working
onor within the machine.
6.Never change or defeat the function of
electricalinterlocks or other machine
“shutdown”switches.
7.Before starting this machine, check that:
-All persons are clear of the machine.
-No maintenance work is being performed
on the machine.
-All guards are in place.
-All parent rolls are well chuckedin the
unwind stands.
-Themachine is free of paper scraps,
wraps and jams.
8.There is a potential hazard of entanglement
inthis machine caused by items such as
longhair,loose clothing and jewelry.
Makesure your clothingand hair fit
closelyto yourbody and that all jewelry,
ringsand watches are removed.
PRO-TECH
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DS-60™
CAL3200
100
90
80
70
60
50
40
30
20
10
SELRST
1234 0000

DS-60 Operation and Maintenance Manual
ii
© GBC Pro-Tech 1998 January
The information in this publication is provided for reference and is believed to be accurate
and complete. GBC Pro-Tech is not liable for errors in this publication or for incidental or
consequential damage in connection with the furnishing or use of the information in this
publication, including, but not limited to, any implied warranty of fitness or merchantabil-
ity for any particular use.
GBC Pro-Tech reserves the right to make changes to this publication and to the products
described in it without notice. All specifications and information concerning products are
subject to change without notice.
Reference in this publication to information or products protected by copyright or patent
does not convey any license under the rights of GBC Pro-Tech or others. GBC Pro-Tech
assumes no liability arising from infringements of patents or any other rights of third par-
ties.
This manual is copyrighted ©1998 by GBC Pro-Tech. All rights reserved. The information
contained in this manual is proprietary and may not be reproduced, stored, transmitted, or
transferred, in whole or in part, in any form without the prior and express written permis-
sion of GBC Pro-Tech.

DS-60 Operation and Maintenance Manual
© GBC Pro-Tech 1998 January
iii
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Caution/Warning Label Locations ...................................................................................1-4
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Preinstallation Checklist ..................................................................................................2-1
Unpacking .......................................................................................................................2-3
Setup ..............................................................................................................................2-4
Leveling ..........................................................................................................................2-5
Startup ............................................................................................................................2-5
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Safety ..............................................................................................................................3-1
Operator Controls ...........................................................................................................3-2
Control Panel ..............................................................................................................3-2
Setup ..............................................................................................................................3-2
Heat Press Roll Pressure ............................................................................................3-2
Loading the Materials .....................................................................................................3-3
Heating ...........................................................................................................................3-3
Process Control Charts ...................................................................................................3-3
Roll to Roll Transfer ........................................................................................................3-3
Sheet Feed Transfer .......................................................................................................3-4
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Thermocouple Positioning and Cleaning ........................................................................4-1
Cleaning ..........................................................................................................................4-2
Adjusting the Main Roll Nip .............................................................................................4-3
Chain Tensioning ............................................................................................................4-4
Lubrication ......................................................................................................................4-5
Contacting Technical Support .........................................................................................4-5
Troubleshooting ..............................................................................................................4-5
Ghosting ......................................................................................................................4-5
Wrinkling .....................................................................................................................4-5
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Limited Warranty .............................................................................................................5-1
Exclusions to the Warranty .........................................................................................5-1
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DS-60 Operation and Maintenance Manual
iv
© GBC Pro-Tech 1998 January
Blank page.

DS-60 Operation and Maintenance Manual
© GBC Pro-Tech 1998 January
1-1
6HFWLRQ6DIHW\
Your safety, as well as the safety of others, is important
to GBC Pro-Tech. This section contains important
safety information.
The following symbols are used throughout this man-
ual to indicate warnings and cautions.
DANGER
WARNING
CAUTION
The DS-60 Heat Press has been designed with safety as
a primary consideration. However, you must become
thoroughly familiar with thecontrols, properoperation,
proper service procedures, and safety features of the
Heat Press before using or servicing the unit.
GBC Pro-Tech DS-60 Heat Press is a powerful
machine that is designed to perform vinyl transfer and
dye sublimation. The forces required to accomplish this
task can vary from negligible to very large.
In addition, the main roll of the DS-60 can reach tem-
peratures of 475 °F (235 °C). At these temperatures
there is a danger of a severe burn if the roll is touched
during set-up, operation or servicing.
Safety is an important feature of the DS-60 Heat Press.
It has emergency stop buttons and photoelectric eye
protection on both the infeed and outfeed sides of the
nipping rolls to prevent objects from entering the nip.
The heat press is equipped with four emergency stop
buttons located on the top front and back of either side
of the heat press. Any of these, if engaged, stops the
heat press. To continue operation all emergency stop
buttons must be in the up position and you must press
the reset button above the fuse panel on the back of the
heat press (see Figure 1-2).
Figure 1-1: Using the Emergency Stop Buttons
Figure 1-2: Resetting the Heat Press
DO NOT ATTEMPT TO OPERATE YOUR
DS-60 HEAT PRESS UNTIL YOU HAVE READ
THIS SECTION CAREFULLY!
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, could result in minor or
moderate injury, or alerts against unsafe
practices, or alerts against actions which could
damage the product.
NOT
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1
/
4
tu
r
n
Twist each button
to resume
operation - the
button pops up
Push any button
to stop the
laminator
Reset Button

Safety
DS-60 Operation and Maintenance Manual
1-2
© GBC Pro-Tech 1998 January
Figure 1-3: Power Lockout
Despite the safety features built into the DS-60 Heat
Press, extreme caution must be used when operating or
servicing the unit. READ THE FOLLOWING
WARNINGS AND CAUTIONS BEFORE
ATTEMPTING TO OPERATE OR SERVICE THE
DS-60 HEAT PRESS.
WARNING
WARNING
WARNING
DANGER
WARNING
Never place fingers or arms between the rolls
when they are turning or when the rolls are in the
closed position. You can be crushed or burned.
Do not wear ties, loose fitting clothing or
dangling jewelry while operating or servicing the
heat press. These items can get caught in the nip
and choke you or you can be crushed or burned.
Do not operate the heat press near water. You can
be severely shocked, electrocuted or cause a fire.
POWER
Insert
Lock
Circuit
Breakers
Secured in
"Off" Position
Remove and lockout power (see Figure 1-3) from
the heat press before servicing. You can be
severely shocked, electrocuted or cause a fire.
Do not use liquid or aerosol cleaners on the heat
press. Do not spill liquid of any kind on the heat
press. You can be severely shocked, electrocuted
or cause a fire. Use only a damp cloth for
cleaning.

DS-60 Operation and Maintenance Manual
© GBC Pro-Tech 1998 January
1-3
WARNING
CAUTION
CAUTION
CAUTION
WARNING
CAUTION
WARNING
WARNING
WARNING
Exercise care when cleaning the rolls with 80%
isopropyl alcohol:
•Use only in a well ventilated area.
•Wear rubber gloves.
•Use only on cool rolls.
Cleaning heated rolls can ignite the fumes.
Use only 80% isopropyl alcohol or a rubber
cement eraser to clean the main rolls. Harsh
chemicals like toluene, acetone or MEK destroy
the silicone covering of the rolls.
Raise the upper main roll when the heat press is
not in operation. Prolonged contact can damage
the rolls.
Excess pressure can damage the main rolls.
Always select the minimum roll pressure
necessary to complete the task.
The operating environment must be free of dust,
flammable liquids and vapors. You can be
injured by inhaling chemical vapors. Vapor build
up or stored flammable liquids can cause a fire.
Excessive dust can damage the heat press.
Do not use a knife or other sharp instrument
during installation or while servicing the heat
press. You can cause irreparable damage to the
rolls.
Do not operate the heat press if the power cord is
damaged or frayed. You can be severely shocked,
electrocuted or cause a fire. Contact a qualified
electrician to replace the cord.
Do not attempt to move the heat press across
anything other than a flat, level surface without
trained and qualified riggers. You can be crushed
or seriously injured.
The DS-60 Heat Press is a large and heavy piece
of equipment. It is necessary to employ
LICENSED RIGGERS ONLY to move the
machine. The heat press is not designed to be
tipped up or sideways in any way. Such action
disturbs the exact alignment of the rolling parts
of the machine and requires extensive
realignment. GBC Pro-Tech’s warranty does not
cover malfunction of the equipment due to
mishandling and/or tipping.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
heat press improperly.
Do not allow anything to rest on the power cord.
Do not locate the cord where people can walk on
it. You or others can be severely shocked,
electrocuted or cause a fire.

Safety
DS-60 Operation and Maintenance Manual
1-4
© GBC Pro-Tech 1998 January
ALWAYS USE GOOD SAFETY PRACTICES WHEN
OPERATING OR SERVICING THE HEAT PRESS
AND KNOW HOW TO REACT QUICKLY IN AN
EMERGENCY.
&DXWLRQ:DUQLQJ/DEHO/RFDWLRQV
Posted at various locations on your DS-60 Heat Press
are important safety labels. PAY CAREFUL ATTEN-
TION TO THESE LABELS AT ALL TIMES! Figure
1-3 shows the location of each of these labels.

DS-60 Operation and Maintenance Manual
© GBC Pro-Tech 1998 January
1-5
Figure 1-4: Locations of Safety Labels
©1994HCS,Inc.800-748-0241ReorderNo.1033R-PT
Crushand burn
hazard. Stay clear
ofmoving rollers.
Stopmachine and
raiseroll before
cleaning.
WARNING
ACHTUNG
MISEEN GARDE
WARNING
ACHTUNG
MISEEN GARDE
NOT
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(Inside cabinet)
(Inside cabinet)
PRO-TECH
DS-60™
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
NOT
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M
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CAL3200
100
90
80
70
60
50
40
30
20
10
SELRST
1234 0000
WARNING
ACHTUNG
MISE EN GARDE
WARNING
ACHTUNG
MISE EN GARDE
WARNING
ACHTUNG
MISE EN GARDE
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
WARNING
ACHTUNG
MISE EN GARDE
©1994 Hazard Communication Systems, Inc. 800-748-0241

Safety
DS-60 Operation and Maintenance Manual
1-6
© GBC Pro-Tech 1998 January
The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Mean-
ing” column) of each decal.
WARNING!
Moving parts can
crush and cut.
Do not operate with
guard or door open.
WARNING!
Crush and burn
hazard. Stay clear of
moving rollers. Stop
machine and raise roll
before cleaning.
WARNING!
Carefully read
Operator's Manual
before handling this
machine. Observe
instructions and safety
rules when operating.
WARNING!
HAZARDOUS
VOLTAGE.
To be serviced only by
trained and authorized
personnel.
Lockout power before
servicing.
Reset.
CAUTION!
Surface is hot.
A burn hazard exists.
WARNING!
1. Read and understand the Operation Manual and
all safety labels before operating this machine.
2. Only a trained person is to be permitted to operate
this machine. Training should include instruction
in operation under normal conditions and
emergency situations.
3. This machine is to be serviced only by trained and
authorized personnel. Follow lockout procedures
before servicing.
4. Never reach into the machine for any reason unless
the machine is at a COMPLETE STOP.
5. Never leave the machine stopped in such a manner
that another worker can start the machine while
you are working on or within the machine.
6. Never change or defeat the function of electrical
interlocks or other machine "shutdown" switches.
7. Before starting this machine, check that:
- All persons are clear of the machine.
- No maintenance work is being performed on
the machine.
- All guards are in place.
- All parent rolls are well chucked in the unwind
stands.
- The machine is free of paper scraps, wraps and
jams.
8. There is a potential hazard of entanglement in this
machine caused by items such as long hair, loose
clothing, and jewelry. Make sure your clothing and
hair fit closely to your body and that all jewelry,
rings and watches are removed.
Decal Meaning Decal Meaning
or
WARNING
ACHTUNG
MISE EN GARDE
WARNING
ACHTUNG
MISE EN GARDE
or
≤100 PSI
≥700 KPa
©1997 HCS, Inc. 800-748-0241 No. 6101-52BVPK
CAUTION!
Rolls are heavy.
Use proper lifting
techniques to prevent
injury.
CAUTION!
Air pressure must be less than 100 PSI (700 kPa) to
avoid damaging the machine.
or
N
O
T
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WARNING!
EMERGENCY STOP BUTTON
Press this button to stop the machine cycle, remove
electric power, and separate (open) rolls to eliminate a
pinch point (on some machines).
Electric power disconnect and lock out location.
WARNING
ACHTUNG
MISE EN GARDE
WARNING
ACHTUNG
MISE EN GARDE
SAFETY
INSTRUCTIONS
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
©1994 Hazard Communication Systems, Inc. 800-748-0241

DS-60 Operation and Maintenance Manual
Installation
© GBC Pro-Tech 1998 January
2-1
6HFWLRQ,QVWDOODWLRQ
GBC Pro-Tech is committed to a program of ongoing
product improvement. As a result, we are providing
these instructions so that you can insure that your new
DS-60 Heat Press is properly and securely unpacked,
moved and installed.
Before a DS-60 Heat Press can be installed, there are a
few requirements that must be met. Make certain that
each of the requirements listed in the following prein-
stallation checklist are met before beginning installa-
tion.
CAUTION
3UHLQVWDOODWLRQ&KHFNOLVW
❏Are doorways and hallways wide enough for the
heat press to be moved to the installation site?
❏Is there ample room for the heat press?
A work area must be established that allows for
operation in both the front and the rear of the
machine and provides space for efficient material
flow. Figure 2-1 shows a typical machine area lay-
out.
❏Is the environment appropriate for the heat press?
The heat press requires a clean, dust and vapor free
environment to operate properly, such as an air
conditioned office area with forced 10% make up
air. However, the heat press must not be located
where there is air blowing directly on it. Major
fluctuation in temperature and humidity are to be
avoided.
WARNING
CAUTION
❏Is there an appropriate power outlet available or
has a certified electrician been contacted to wire
the heat press directly?
The heat press requires 30A single phase service
and a power receptacle that accepts a 30A 250V
NEMA L6-30P plug.
WARNING
WARNING
WARNING
WARNING
Failure to follow the preinstallation checklist can
result in damage to the heat press.
The operating environment must be free of dust,
flammable liquids and vapors. You can be
injured by inhaling chemical vapors. Vapor build
up or stored flammable liquids can cause a fire.
Excessive dust can damage the heat press.
Do not locate the heat press where air is blowing
directly on the machine. The air flow can cool the
rolls unevenly and result in poor quality output.
Do not attempt to defeat the grounding feature of
the ground plug on the heat press. You can be
severely shocked, electrocuted or cause a fire.
The three prong plug fits only into a grounding-
type power outlet. If you are unable to insert the
plug into the existing outlet, contact a qualified
electrician to replace the obsolete outlet.
Do not use an extension cord on this heat press.
You can be severely shocked, electrocuted or
cause a fire. If you need a longer cable contact a
qualified electrician.
Do not operate the heat press if the power cord is
damaged or frayed. You can be severely shocked,
electrocuted or cause a fire. Contact a qualified
electrician to replace the cord.
Do not allow anything to rest on the power cord.
Do not locate the cord where people can walk on
it. You or others can be severely shocked,
electrocuted or cause a fire.

Installation
DS-60 Operation and Maintenance Manual
2-2
© GBC Pro-Tech 1998 January
Figure 2-1: Heat Press Space Requirements
80" (~2 m)
3' (~1 m)
Wall
2'9"
(~.84 m)
8'6-1/2"
(~2.6 m)
8'6-1/2"
(~2.6 m)
Rear
Front
20'
(~6 m)
Electrical
Supply
13' (~4 m)

DS-60 Operation and Maintenance Manual
Installation
© GBC Pro-Tech 1998 January
2-3
8QSDFNLQJ
☞
NOTE
ALL SHIPMENTS ARE EX- WORKS. At our dock title
passes to the buyer. Please review your insurance cov-
erage prior to shipment, as you are responsible for all
subsequent freight charges and risks. Before signing
the Bill of Lading you should be sure to inspect the
crate and/or pallet for signs of damage or missing
items; if applicable, make a note of this on the Bill of
Lading.
The DS-60 Heat Press is shipped in a wood crate on a
skid.
WARNING
Tools required:
• Phillips head screwdriver
•7/8" open end wrench or adjustable wrench
To uncrate the heat press:
1. Remove the top of the crate and then the sides in
the order shown in Figure 2-2.
CAUTION
Figure 2-2: Removing the Crate
2. Gently unwrap the shrink wrap from around the
heat press.
CAUTION
3. Carefully remove any accessories packed with the
heat press. The accessory pack should contain:
1 Set, hex wrenches
1 Slitting knife
1 Manual
1 Set, spare fuses
1 Tape measure
1 Roll of masking tape
1 100% cotton terry cloth
1 Bottle 80% isopropyl alcohol
4 Leveling studs
4 Leveling pads
4. Have the heat press rolled off the skid and placed
on the floor by licensed riggers. The ramps
included with the heat press can be secured to the
edge of the crate bottom using the screws left over
from the crate disassembly (see Figure 2-2).
The unpacking process requires at least two
people. You can be severely injured or crushed.
Do not allow the top to fall into the crate. It can
damage the heat press.
Do not put packing screws on the floor. They can
cause problems when trying to roll the machine
into position.
A second person must support the side labeled (5)
in Figure 2-2. It can fall and damage the heat
press.
Do not use a knife or other sharp instrument
during installation or while servicing the heat
press. You can cause irreparable damage to the
rolls.
5
4
2
Install
Screws
©1994HCS,Inc.800-748-0241ReorderNo.1033-PT
Crushandburn
hazard.Stayclear
ofmovingrollers.
Stopmachineand
raiserollbefore
cleaning.
WARNING
ACHTUNG
MISEENGARDE
©1994HCS,Inc.800-748-0241ReorderNo.1033R-PT
Crushandburn
hazard.Stayclear
ofmovingrollers.
Stopmachineand
raiserollbefore
cleaning.
WARNING
ACHTUNG
MISEENGARDE
PRO-TECH
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DS-60™
CAL3200
100
90
80
70
60
50
40
30
20
10
SEL RST
1234 0000
1
3

Installation
DS-60 Operation and Maintenance Manual
2-4
© GBC Pro-Tech 1998 January
WARNING
5. Remove any plastic strapping and packing paper
taped to the rolls.
CAUTION
6. Remove all packing materials to a safe distance
from the heat press.
☞
A NOTE ABOUT RECYCLING
The crate components can be reused for shipping the
machine again, or can be disassembled and the wood
and screws recycled. The shrink wrap is not recyclable,
however, so it must be discarded.
7. Level the heat press using the procedure later in
this section.
6HWXS
Once the DS-60 Heat Press has been unpacked and
moved into final position check each of the following
items.
Tools required:
•1/8" hex wrench
• Adjustable wrench
Setup Procedure
1. Inspect the heat press for any obvious shipping
damage.
2. Remove the left and right side cabinet covers with
the 1/8" hex wrench by removing the eight screws
holding each cover in place.
3. Inspect all the bolts and tighten any that were loos-
ened during shipping.
4. Set the nip. (See Maintenance for the procedure.)
5. Verify that thermocouple makes contact with the
upper main roll. (See Maintenance for the proce-
dure.)
WARNING
6. Replace both cabinet covers.
Do not attempt to move the heat press across
anything other than a flat, level surface without
trained and qualified riggers. You can be crushed
or seriously injured.
The DS-60 Heat Press is a large and heavy piece
of equipment. It is necessary to employ
LICENSED RIGGERS ONLY to move the
machine. The heat press is not designed to be
tipped up or sideways in any way. Such action
disturbs the exact alignment of the rolling parts
of the machine and requires extensive
realignment. GBC Pro-Tech’s warranty does not
cover malfunction of the equipment due to
mishandling and/or tipping.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
heat press improperly.
Do not use a knife or other sharp instrument
during installation or while servicing the heat
press. You can cause irreparable damage to the
rolls.
ALWAYS CHECK THE POSITION AND
CONDITION OF THE THERMOCOUPLE
PRIOR TO OPERATION! The thermal junction
of the thermocouple MUST make contact with
the upper main roll to maintain proper roll
operating temperatures. The thermocouple must
also be free of adhesive and dirt. The roll can
overheat and cause a fire or seriously damage the
heat press.

DS-60 Operation and Maintenance Manual
Installation
© GBC Pro-Tech 1998 January
2-5
/HYHOLQJ
Tools required:
• Adjustable wrench
• Carpenter's level
To level the heat press:
1. Raise each end, remove the castors and install a
leveling pad and stud onto each of the foot brackets
at the four bottom corners of the heat press. Thread
third nut on stud above foot bracket.
2. Thread stud into 4 leveling pads lock down with
nut. Thread second nut onto stud.
3. Place a carpenter's level front to rear across the two
lower tie bars at one end of the machine.
4. Level this end of the machine front to rear, raising
or lowering the leveling pads by adjusting the mid-
dle nuts on the foot bolts.
5. Move the level to the other end of the machine and
level front to rear.
6. Place the level directly on one of the tie bars and
level the machine side to side.
7. Recheck the front to rear level condition to insure
that it has not changed. If it has, repeat the leveling
procedure.
8. When all the measurements indicate that the
machine is level, tighten down the top nuts on the
foot brackets to lock the pads in their current posi-
tion.
6WDUWXS
The first time the heat press is started and every time it
is serviced you should use the following checklist to
confirm that the unit is operating properly and that all
safety mechanisms are functioning.
Startup Checklist
Start the heat press and go through the following
checklist.
❏Are the emergency stop buttons working?
Push down on one of the emergency stop buttons.
The heat press should stop. Pull up on the button
and push the reset button on the lower back of the
heat press. The heat press should resume operation.
Always check all buttons.
WARNING
❏Is the photoelectric eye system working?
With the heat press running, place an object
approximately the size of your hand just in front of
the nip to confirm that the photoelectric eye system
is functioning. The rolls should stop. Move the
object away from the nip. Press the Photoelectric
Eye Reset button on the front control panel. The
heat press should resume operation.
WARNING
❏Is the motor functioning?
Test the motor at various speeds ranging from
0-18. At 0 the rolls should stop turning.
Run the motor in both forward and reverse.
❏Are the heaters working?
Verify that the heater controller heats the top roll.
Once you have completed the startup checklist you can
safely run a test sample.
Never operate the heat press unless all of the
emergency stop buttons are functioning properly.
You can be crushed or burned.
Never operate the heat press unless the
photoelectric eye system is functioning properly.
You can be crushed or burned.

Installation
DS-60 Operation and Maintenance Manual
2-6
© GBC Pro-Tech 1998 January
Blank page.

DS-60 Operation and Maintenance Manual
Operation
© GBC Pro-Tech 1998 January
3-1
6HFWLRQ2SHUDWLRQ
6DIHW\
GBC Pro-Tech DS-60 Heat Press is a powerful
machine that is designed to perform dye sublimation.
The forces required to accomplish this task can vary
from negligible to very large.
In addition, the main roll of the DS-60 can reach tem-
peratures of 475 °F (235 °C). At these temperatures
there is a danger of a severe burn if the roll is touched
during set-up, operation or servicing.
The DS-60 Heat Press has a steel cabinet that is bolted
closed to isolate the electrical and drive system compo-
nents for the safety of the operator. Only a qualified
service technician should open these cabinets.
The heat press is equipped with four emergency stop
buttons located on the top front and back of either side
of the heat press. Any of these, if engaged, stops the
heat press. To continue operation all emergency stop
buttons must be in the up position and you must press
the reset button above the fuse panel on the back of the
heat press (see Figure 3-2).
Figure 3-1: Using the Emergency Stop Buttons
Figure 3-2: Resetting the Heat Press
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Twist each button
to resume
operation - the
button pops up
Push any button
to stop the
laminator
Reset Button

Operation
DS-60 Operation and Maintenance Manual
3-2
© GBC Pro-Tech 1998 January
2SHUDWRU&RQWUROV
The operator controls for the DS-60 Heat Press are
located on the front and rear of the unit, to the right of
the operator position. The names and functions of these
controls are as follows:
&RQWURO 3DQHO
Figure 3-3: Control Panel
1. ROLL PRESSURE DISPLAY - Displays the
pressure pushing the main roll down.
2. SPEED ADJUSTMENT – Adjusts the speed of
the machine from zero to the maximum as the con-
trol is turned clockwise. (Turtle is slow, rabbit is
fast.)
3. SLOW MODE CONTROL – Switches the photo-
electric eye system on and off. If the left side of the
toggle switch is pressed, the photoelectric eye sys-
tem is on and the heat press runs at any speed. If
the right side of the toggle switch is pressed, the
photoelectric eye system is off and the heat press
runs only by using the footswitch and only at
1 m/min maximum speed.
4. UPPER ROLL HEATER CONTROLLER –
Provides a readout of the temperature of the upper
roll and the set-point for the desired temperature.
5. UPPER ROLL HEAT ON/OFF – Turns the
heater controller for the upper main roll on or off.
6. TACHOMETER/COUNTER DISPLAY – Dis-
plays the operational rate or the amount of material
processed.
7. MOTIONCONTROLFORWARD/REVERSE -
Controls the direction of the drive system, forward,
reverse, or stop.
8. RUN/STOP – Turns the drive system on or off.
9. PHOTOELECTRIC EYE RESET – Resets the
photoelectric eye system. (The photoelectric eye
system must be reset any time the heat press is
turned off and back on.)
6HWXS
Setup of the DS-60 Heat Press is quick and straightfor-
ward when instructions are followed exactly.
To adjust the nip, please see Maintenance.
+HDW 3UHVV 5ROO 3UHVVXUH
Use only the minimum amount of roll pressure needed
to accomplish the task. Excess pressure can damage the
rolls. Wrinkles and ripples have causes that generally
cannot be cured by applying more pressure.
CAUTION
A maximum rollpressure for dye sublimation is 40% at
390-400 ºF (199-204 ºC) with a suggested speed of 2-3
fpm (60-90 cpm).
CAL 3200
2
Speed
Adjustment
100
90
80
70
60
50
40
30
20
10
SEL RST
1
Roll
Pressure
Display
1234 0000
4
5
6
7
RUN/STOP
8
9
3
Slow Mode
Control
Tachometer/Counter
Display
Upper Roll Heat
ON/OFF
Motion Control
FORWARD/REVERSE
Photoelectric Eye
Reset
Upper Roll Heater
Controller
Excess pressure can damage the main rolls.
Minimum heat press roll pressure is consistent
with good results.

DS-60 Operation and Maintenance Manual
Operation
© GBC Pro-Tech 1998 January
3-3
/RDGLQJWKH0DWHULDOV
Loading the materials is very simple. Remove the
unwind shaft from the position where the material is to
be installed. Slide the material onto the unwind shaft,
making sure that the orientation of the roll is correct.
Return the unwind shaft and material to the machine
and center the material between the side frames using a
tape measure. Once all the materials are loaded, the
machine can then be webbed. Some fabrics have a right
and a wrong side based on the fabric bias.
+HDWLQJ
Use the following instructions when heating the upper
main roll.
1. Set the heater switch to ON.
2. Adjust the temperature controller for the desired
operating temperature using the temperature con-
troller push buttons.
3. When heating the rolls, keep the top roll down and
turning at a moderate speed to prevent uneven
heating.
4. It will take approximately 30 minutes for the main
roll(s) to reach operating temperature. When the
preset operating temperature has been reached, the
machine is ready to use.
3URFHVV&RQWURO&KDUWV
Process control charts allow you to record the way you
thread material through the machine's rolls and idlers
(called webbing) and the control settings for each prod-
uct and process. Process control charts are an excellent
tool for training new operators. They provide a "road
map" for correct machine setup and operation.
This section contains a blank process control chart and
diagram for the DS-60 as well as completed charts for
the basic operations of the heat press.
GBC Pro-Tech Heat Presses respond in a very accurate
and repeatable manner. The charts provide a way to set
up each time, every time for repeatable performance by
assuring that all controls are set to optimum.
The process control charts should be kept in this man-
ual or in a book close to the heat press. Encapsulate the
popular charts so they can withstand food and coffee
spills and so they are always available for ready refer-
ence.
☞
NOTE
When trying new products and processes, remember
that GBC Pro-Tech's customer service representatives
are only a phone call away.
5ROOWR5ROO7UDQVIHU
1. See process chart 3-2 and diagram 3-2a.
2. Make sure the infeed idler assembly is in the low-
ered position.
3. Set the heater controller to operational temperature
and confirm that it is rotating with the lower main
roll.
4. Once the upper main roll is at operating tempera-
ture, center the fabric and transfer paper on the
unwinds and secure.
5. Stop the rolls from turning and raise the upper
main roll.
6. Web the fabric through the machine, based on its
bias characteristics, all the way to the rear lower
rewind.
7. Web the transfer paper through the main roll nip
and lower to the main roll. Make sure the fabric
and paper are taut while webbing the machine.
8. Pivot the idler assembly into its up position and
secure it.
9. Start the heat press turning and take the transfer
paper up to the upper rewind and tape it to the
rewind.
10. Begin transfer.
11. To stop the transfer, stop the machine, lower the
idler assembly, and raise the main roll. The web
can be left this way indefinitely.
12. Heat Press Roll Pressure: 40% maximum.
13. Speed: 1-4 fpm (30-90 cpm).
14. Upper Heat Press Roll Heat: 395 °F (200 °C) max-
imum.

Operation
DS-60 Operation and Maintenance Manual
3-4
© GBC Pro-Tech 1998 January
6KHHW)HHG7UDQVIHU
1. See process chart 3-3 and diagram 3-3a.
2. Make sure the infeed idler assembly is in the low-
ered position.
3. Set the heater controller to operational temperature
and confirm that it is rotating with the lower main
roll.
4. Once the upper main roll is at operating tempera-
ture, center the craft paper on the unwind and
secure.
5. Stop the rolls from turning and raise the upper
main roll.
6. Web the craft paper through the machine all the
way to the rear lower unwind.
7. Pivot the idler assembly into its up position and
secure it.
8. Perform the transfer by inserting the materials into
the craft paper/main roll nip using the infeed table.
9. Start the heat press.
10. To stop the transfer, stop the machine, lower the
idler assembly, and raise the main roll. The web
can be left this way indefinitely.
11. Heat Press Roll Pressure: 40% maximum.
12. Speed: 1-4 fpm (30-90 cpm).
13. Upper Heat Press Roll Heat: 395 °F (200 °C) max-
imum.